Deformable ear tip for earphone and method therefor

ABSTRACT

A removable component for use with an earphone is disclosed. As an example, the removable component can be an ear tip. According to one aspect, an improved ear tip can be provided for use with a headphone. The ear tip is suitable for in-ear operation and can have a cosmetic deformable outer member. The deformable outer member can enable the ear tip to readily conform to a user&#39;s ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. Methods for forming such ear tips are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/794,690, filed Jun. 4, 2010 now U.S. Pat. No. 8,280,093, entitled“DEFORMABLE EAR TIP FOR EARPHONE AND METHOD THEREFOR”, which is herebyincorporated herein by reference, which in turn is aContinuation-In-Part of U.S. patent application Ser. No. 12/205,748,filed Sep. 5, 2008 now U.S. Pat. No. 8,270,656, entitled “REMOVABLE EARTIP FOR EARPHONE”, which is hereby incorporated herein by reference, andwhich in turn claims priority benefit of: (i) U.S. Provisional PatentApplication No. 61/230,065, filed Jul. 30, 2009, entitled “DEFORMABLEEAR TIP FOR EARPHONE”, which is hereby incorporated herein by reference;and (ii) U.S. Provisional Patent Application No. 61/240,582, filed Sep.8, 2009, entitled “DEFORMABLE EAR TIP FOR EARPHONE”, which is herebyincorporated herein by reference.

BACKGROUND OF THE INVENTION

Several different approaches can be used to provide audio from anelectronic device to a user. For example, the electronic device mayinclude or be coupled to a speaker or speaker system operative toprovide audio. As another example, the electronic device may be coupledto a headset or headphone for providing audio directly to the user'sears. A headset or headphone (or earphone) is a device that convertselectric signals, such as from an electronic device, to audible soundand fits over or in a user's ear. Headphones come in various types andconfigurations. One type of headset or headphone is over-the-ear, andanother type of headset or headphone is in-ear.

To improve a user's comfort, a headset or headphone may include one ormore elements operative to provide a pleasant interface between theaudio components of the headset (e.g., the ear piece) and the user'sears. For example, some headsets or headphones may include anover-the-ear type ear piece that is operative to be placed on or overthe user's ear. The ear piece may include one or more foam or clothcomponents that provide a compliant fit against the user's ear. Asanother example, some headsets or headphones may include an in-the-eartype ear piece (e.g., an ear bud) operative to fit inside the user'sear.

In-ear headsets or headphones offer superior audio performance.Unfortunately, however, in-ear headsets or headphones have difficultyproviding a proper fit with a user's ear while also being comfortablewhile being worn.

SUMMARY

The invention pertains to a removable component for use with anearphone. As an example, the removable component can be an ear tip andthe ear tip can be at least partially deformable.

According to one aspect, the invention can pertain to an ear tip for usewith a headphone. The ear tip can include a deformable outer member andis suitable for in-ear operation. The deformable outer member enablesthe ear tip to readily conform to a user's ear. The ear tip can alsoinclude an inner member to structurally support the outer member and tofacilitate attachment to a headphone. The deformable outer member can beconfigured to deform around the inner member. The deformable outermember can be provided with a durable outer surface that can becosmetically pleasing.

The invention may be implemented in numerous ways, including, but notlimited to, as a system, device, apparatus, or method. Exemplaryembodiments of the invention are discussed below.

As an ear tip for a headphone, one embodiment can include at least aninner cylindrical structure configured to removably attach to theheadphone, and an outer spherical structure integral with or adhered toat least a top end and sides of the inner cylindrical structure. Theouter spherical structure can be formed at least partially from adeformable material. The deformable material can also include a cosmeticsurface.

As an ear tip for a headphone, another embodiment can include at leastan inner cylindrical structure configured to removably attach to theheadphone, and an outer spherical structure integral with or adhered toat least sides of the inner cylindrical structure. The outer sphericalstructure can be formed at least partially from a deformable material.The inner cylindrical structure can also extend substantially throughthe ear tip.

As an ear tip for a headphone, still another embodiment can include atleast an inner cylindrical structure configured to removably attach tothe headphone, and an outer rounded structure integral with or adheredto said inner cylindrical structure. The outer rounded structure beingformed at least partially from a deformable material. The ear tip canalso include an outer film provided around the outer spherical structureto provide an outer surface for the ear tip.

As a method for forming ear tips, one embodiment can include at leastconfiguring a molding station having a top and bottom molding plates,first compression molding an inner structure using a first moldablematerial, and curing the formed inner structure. Thereafter, the methodcan include at least reconfiguring the molding station by replacing oneof the top and bottom molding plates, second compression molding atleast a portion of an outer structure using a second moldable material,and curing the at least a portion of the outer structure that has beenformed by the second compression molding. The method can then concludeby removing a resulting ear tip from the molding station.

A method for forming ear tips, another embodiment can include at leastconfiguring a molding station having a top and bottom molding plates,first compression molding an outer structure using a first moldablematerial, and curing the formed outer structure. Thereafter, the methodcan include at least reconfiguring the molding station by replacing atleast one of the top and bottom molding plates, second compressionmolding at least a portion of an inner structure using a second moldablematerial, and curing the at least a portion of the inner structure thathas been formed by the second compression molding. The method can thenconclude by removing a resulting ear tip from the molding station.

As method for forming an ear tip, another embodiment can include atleast providing an inner structure for an ear tip, providing a top moldhaving at least one protrusion, and providing a bottom mold having anear tip cavity. The method can also include at least depositing aquantity of a second material into and/or adjacent the ear tip cavity,and coupling the top and bottom molds together with the protrusion beinginserted into the cavity. Still further, the method can include at leastcuring the ear tip being formed within the cavity, and removing theformed ear tip from the bottom mold.

As a method for forming an ear tip, still another embodiment can includeat least forming an inner structure for an ear tip, providing a top moldhaving at least one protrusion, and providing a porous bottom moldhaving an ear tip cavity. Further, the method can include placing asheet of a first material over the cavity, wherein the sheet being usedto form an outer film for the ear tip, depositing a quantity of a secondmaterial on the sheet and adjacent the cavity, and applying a vacuum tothe porous bottom mold to draw the sheet of the first material and theat least a portion of the deposited second material into the cavity. Inaddition, the method can include placing the molded inner structure ontothe protrusion, heating the cavity, and coupling the top and bottommolds together with the protrusion being inserted into the cavity. Stillfurther, the method can include curing the ear tip being formed withinthe cavity. Following curing, the method can further include removingthe top mold, removing excess portions of the first material and thesecond material, and removing the formed ear tip from the bottom mold.

As an ear tip for a headphone, one embodiment of the invention can, forexample, include at least: an inner cylindrical structure configured toremovably attach to the headphone; and an outer spherical structureintegral with or adhered to a top end of the inner cylindrical structurebut having an air interface between the outer spherical structure andthe inner cylindrical structure at a bottom end.

As an ear piece for a headphone, one embodiment of the invention can,for example, include at least: an inner structure that providesstructural support for the ear piece; and an outer structure integrallyformed about the inner structure, the output structure being deformableso as to deform during in-ear usage.

As a method for forming deformable ear tips, one embodiment of theinvention can, for example, include at least: configuring a first topmolding plate and a first bottom molding plate at a molding station;first compression molding a plurality of inner structures using a firstmolding material and the configured first top molding plate and thefirst bottom molding plate; curing the inner structures that have beenformed by the first compression molding; reconfiguring the moldingstation by replacing the first top molding plate with a second topmolding plate; second compression molding a plurality of outerstructures using a second molding material and the configured second topmolding plate and the first bottom molding plate; curing the outerstructures that have been formed by the second compression molding; andremoving ear tips that have been formed from the molding plates.

As a method for forming deformable ear tips, another embodiment of theinvention can, for example, include at least: configuring top and bottommolding plates at a molding station; first compression molding aplurality of inner structures using the configured top and bottommolding plates and a first molding material; curing the inner structuresthat have been formed by the first compression molding; reconfiguringthe molding station by replacing one of the top and bottom moldingplates; second compression molding a plurality of outer structures usinga second molding material; curing the outer structures that have beenformed by the second compression molding; and removing ear tips thathave been formed from the molding plates.

Various aspects and advantages of the invention will become apparentfrom the following detailed description taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, in which:

FIGS. 1A-1B are diagrams illustrating a headphone according to oneembodiment of the invention.

FIGS. 2A-2C are diagrams illustrating a headphone according to oneembodiment of the invention.

FIG. 3 is a perspective view of a front body according to one embodimentof the invention.

FIG. 4 is a perspective assembly diagram for a front body assemblyaccording to one embodiment of the invention.

FIG. 5 is a side view of a cap body according to one embodiment of theinvention.

FIG. 6 is a cross-sectional view of a cap body according to oneembodiment of the invention.

FIG. 7 is a cross-sectional view of an output portion of a front bodyaccording to one embodiment of the invention.

FIG. 8 is a cross-sectional view of a front body according to oneembodiment of the invention.

FIGS. 9A-9E are views of an ear tip according to one embodiment of theinvention.

FIGS. 10A-10E are views of an ear tip according to another embodiment ofthe invention.

FIGS. 11A-11E are views of an ear tip according to still anotherembodiment of the invention.

FIG. 12 is a flow diagram of an ear tip formation process according toone embodiment of the invention.

FIG. 13 is a flow diagram of an ear tip formation process according toanother embodiment of the invention.

FIG. 14 is a flow diagram of an ear tip formation process according tostill another embodiment of the invention.

FIG. 15 is a cross-sectional representation of an ear tip which includesa plurality of layers according to an embodiment of the invention.

FIG. 16 is a flow diagram of an ear tip formation process according toyet another embodiment of the invention.

FIG. 17 illustrates an ear tip 1700 with an extended inner structureaccording to one embodiment of the invention.

FIG. 18 is a perspective view of an ear tip with an extended innerstructure according to one embodiment of the invention.

FIG. 19A is a rear view, FIG. 19B is a side view, and FIG. 19C is across-sectional view for an ear tip with an extended inner structure.

FIGS. 20A and 20B illustrates a flow diagram of an ear tip formationprocess according to one embodiment.

FIGS. 21A-21G are cross-sectional diagrams illustrating ear tipformation according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention pertains to a removable component for use with anearphone. As an example, the removable component can be an ear tip andthe ear tip can be at least partially deformable.

According to one aspect, the invention can pertain to an ear tip for usewith a headphone. The ear tip can include a deformable outer member andis suitable for in-ear operation. The deformable outer member enablesthe ear tip to readily conform to a user's ear. The ear tip can alsoinclude an inner member to structurally support the outer member and tofacilitate attachment to a headphone. The deformable outer member isconfigured to deform around the inner member. The deformable outermember can be provided with an outer cosmetic surface.

Exemplary embodiments of aspects of the invention are discussed belowwith reference to the various figures. However, those skilled in the artwill readily appreciate that the detailed description given herein withrespect to these figures is for explanatory purposes, as the inventionextends beyond these embodiments. It should be noted that theembodiments are in many cases are not depicted in an actual orconsistent scale. For example, embodiments are often depicted largerthan actual product size for ease of illustration.

FIGS. 1A-1B are diagrams illustrating a headphone 100 according to oneembodiment of the invention. FIG. 1A is a side view of the headphone100, and FIG. 1B is a front view of the headphone 100. The headphone 100can also be referred to as an earphone.

The headphone 100 includes a front body 102 and a rear body 104. Thefront body 102 is attached to the rear body 104. Alternatively, thefront body 102 and rear body 104 can be formed as a unitary structure.The headphone 100 can also include an ear tip 106. The ear tip 106 is adeformable structure capable of conforming to a user's ear when beingused by a user. The ear tip 106 can attach to a protruding portion 108on the front body 102. Still further, as illustrated in FIG. 1B, the eartip 106 can include an opening 110. The opening 110 exposes a cover 112provided on a top end of the protruding portion 108 of the front body102. As one example, the cover 112 can be a mesh cover, such as a screen(e.g., stainless steel screen). The top end of the protruding body 108is adjacent the opening 110 in the ear tip 106. To provide audio soundfor the user, the headphone 100 provides an acoustic channel internal tothe front body 102. For proper output of quality audio sound from theheadphone 100, the acoustic channel needs to remain substantially freefrom foreign matter that may collect in the acoustic channel. Byproviding the cover 110 at the top end of the protruding body 108, thecover 110 can serve to substantially prevent foreign matter, such ashuman debris (e.g., ear wax), from entering into the acoustic channel.

FIGS. 2A-2C are diagrams illustrating a headphone 200 according to oneembodiment of the invention. FIG. 2A is a perspective view of theheadphone 200, FIG. 2B is a side view of the headphone 200, and FIG. 2Cis a front view of the headphone 200. The headphone 200 includes a frontbody 202 and a rear body 204. The front body 202 and the rear body 204can be separately formed parts that can be assembled together to form ahousing for the headphone 200. In one implementation, the front body 202is secured to the rear body 204 by mechanical features, such as notches,detents, recesses, threads, or adhesives. In another implementation, thefront body 202 and the rear body 204 can be formed as a unitarystructure.

The front body 202 includes a removable cap 206. The removable cap 206can include a plurality of the knurls 208. In this embodiment, it isintended that the removable cap 206 be removable from the headphone 200by a user. Hence, the knurls 208, if provided, can assist the user withremoval of the removable cap 206 from the headphone 200 or attachment ofthe removable cap 206 to the headphone 200. As shown in FIGS. 2A and 2B,the removable cap 206 can be removably attached to a top end of aprotruding portion 210 of the front body 210.

The front body 202 encloses an acoustic channel that is used to providesound to a user of the headphone 200. As such, acoustic channel extendsthrough the center of the front body 202. Further, the removable cap 206includes a central opening so that the sound being provided via theacoustic channel can emit from the headphone 200. As shown in FIG. 2C,the headphone 200 can also include a mesh cover 212 provided on orwithin the removable cap 206. Advantageously, the mesh cover 212 isplaced at the end of the acoustic channel with respect to the front body202. The mesh cover 212 is thereby able to substantially prevent foreignmatter, such as human debris, from entering into the acoustic channel.If significant foreign matter is able to enter the acoustic channel, theacoustical characteristics and the ability for the headphone 200 toproperly output sound to its user can be substantially hindered. Hence,the mesh cover 212 serves to substantially block foreign matter fromentering the acoustic channel. If the mesh cover 212 becomes clogged,the removable cap 206 can be removed from the front body 202 and themesh cover 212 can be serviced (e.g., cleaned to remove accumulatedforeign debris).

The front body 202, the rear body 204, the removable cap 206 and themesh cover 212 can be formed of the same or different materials (e.g.,plastic, ceramic, metals, nylon, etc.). In one implementation, the rearbody 204 can be plastic, and the front body 202, the removable cap 206and the mesh cover 212 can be metal (e.g., stainless steel).

FIG. 3 is a perspective view of the front body 300 according to oneembodiment of the invention. The front body 300 is, for example,suitable for use as the front body 202 illustrated in FIGS. 2A-2C.

The front body 300 includes a base portion 302 and an output portion306. The base portion 302 can be integrally formed with the outputportion 306. Alternatively, the base portion 302 and the output portion306 can be separate parts that are assembled together to form the frontbody 300. A bottom end of the base portion 302 includes an opening 304.The opening 304 allows the front body 300 to be attached to a rear body,such as the rear body 104 illustrated in FIGS. 1A and 1B or the rearbody 204 illustrated in the FIGS. 2A-2C. In addition, the front body 300can include a removable cap 308. The removable cap 308 can attach to theoutput portion 306. As shown in FIG. 3, the removable cap 308 is able tobe attached to a top end of the output portion 306.

FIG. 4 is a perspective assembly diagram for a front body assembly 400according to one embodiment of the invention. The front body assembly400, once assembled, can pertain to the front body 700 illustrated inFIG. 3.

The front body assembly 400 includes a front body 402. The front body402 includes a base portion 404 and an output portion 406. The outputportion 406 can correspond to a protruding portion of the front body402. As illustrated in FIG. 4, at the end of the protruding portion ofthe output portion 406, various components can be inserted in orattached to the output portion 406. Specifically, as shown in FIG. 4, aninternal mesh 408 can be placed internal to an opening 409 of the outputportion 406. In addition, an internal gasket 410 can be placed withinthe opening 409 of the output portion 406. The output portion 406 canalso receive a cap body 412. In one embodiment, the cap body 412includes threads 414. The opening 409 in the output portion 406 can alsoinclude threads. In such case, the cap body 412 can be screwed into theopening 409 in the output portion 406. When the cap body is screwed intothe opening 409 in the output portion 406, the internal gasket 410 canserve to further secure the cap body 412 within the opening 409 of theoutput portion 406. The internal gasket 410 can provide a compliantsurface that can be compressed when the cap body 412 is screwedcompletely into the opening in the output portion 406. The internal mesh408 can be secured within the opening 409 in the output portion 406 byadhesive and/or by the internal gasket 410. The internal gasket 410 canbe sized such that even with the cap body 412 removed from the opening409 in the output portion 406, the internal mesh 408 remains secured inthe opening 409. However, should the internal mesh 408 need to beremoved, the internal gasket 410 is conformable such that it can beremoved from the opening 409 thereby allowing the internal mesh 408 toalso be removed for servicing. The front body assembly 400 can alsoincludes an outer mesh 416. The outer mesh 416 can be secured to a topsurface of the cap body 412.

Although the internal mesh 408 and the outer mesh 416 are utilized, theacoustic channel provided through the opening 409 in the output portion406 is not blocked by any of the components of the front body assembly400 being inserted or coupled to the output portion 406. In this regard,the internal gasket 410 is ring-shaped, and the cap body 412 is hollowor tubular. Further, the internal mesh 408 and the outer mesh 416include numerous openings within the mesh structures that allow soundfrom the acoustic channel to properly emit from the front body assembly400. In other words, the internal mesh 408 and the outer mesh 416 aresubstantially acoustically neutral.

The parts of the front body assembly 400 can be formed of differentmaterials (e.g., plastic, ceramic, metals, nylon, etc.). In oneimplementation, the front body 402 can be metal, the internal mesh 408can be metal, the internal gasket 410 can be rubber, the cap body 412can be metal, and the outer mesh 416 can be metal. As one example, themetal can be stainless steel.

FIG. 5 is a side view of a cap body 500 according to one embodiment ofthe invention. The cap body 500 includes a bottom portion 502 and a topportion 504. In the bottom portion 502 includes threads 506. The topportion 504 includes knurls 508.

FIG. 6 is a cross-sectional view of a cap body 600 according to oneembodiment of the invention. The cap body 600 includes a bottom portion602 and a top portion 604. The bottom portion 602 has external threads606. The top portion 604 includes knurls 608 about the periphery of thetop portion 604. In addition, the cap body 600 includes a recess region610 for receiving a cover, such as a mesh cover. Additionally, the capbody 600 has an opening 612 that extends therethrough. The opening 612couples to, extends to or is part of the acoustic channel for a frontbody (e.g., cap body 402) to which the cap body 600 is attached. Theopening 612 internal to the cap body 600 can further include internalthreads 614. The internal threads 614 do not serve a mechanical purposebut have been shown to have beneficial acoustic impact on acousticalcharacteristics of the acoustic channel.

FIG. 7 is a cross-sectional view of an output portion 700 of a frontbody according to one embodiment of the invention. The output portion700 includes a tapered structure 702 and an output structure 704. Acentral portion of the output portion 700 extends an opening 706 whichprovides an acoustic channel through the output portion 700. Internal tothe output structure 704 are threads 708 for receiving compatiblethreads of a removable cap (e.g., cap body 412, 500, 600). Although theoutput portion 700 utilizes threads 708 to secure a removable cap to theoutput portion 700, it should be recognized that in other embodimentsdifferent techniques can be utilized to secure a removable cap to theoutput portion 700.

FIG. 8 is a cross-sectional view of a front body 800 according to oneembodiment of the invention. As illustrated in FIG. 8, the front body800 is fully assembled. Initially, it is noted that the front body 800includes a base portion 802. The base portion 802 serves to connect to arear body of a headphone (e.g., rear body 104, 204). The front body 800also includes an output portion 804. The output portion 804 is, forexample, constructed as is the output portion 700 illustrated in FIG. 7.Additionally, a removable cap 806 has been attached to the outputportion 804. In particular, the removable 806 has been screwed into thethreaded opening in a top end of the output portion 804. The removablecap 806 can have an outer mesh 808 secured to a top end of the removablecap 806. The outer mesh 808 can be secured to the top end of theremovable cap 806 by interference (frictional) fitting, adhesive,notches, protrusions, and the like. Additionally, an internal mesh 810and a gasket 812 can be provided within the threaded opening of theoutput portion 804. As illustrated in FIG. 8, the gasket 812 can beprovided in the opening of the output portion 804 between the internalmesh 810 and a forward end of the removable cap 806 while inserted. Whenthe removable cap 806 is screwed into the threaded opening of the outputportion 804, the gasket 812 can be compressed, which thereby serves toprevent the removable cap 806 from loosening. Hence, the gasket 812 canbe considered as a retention device for the removable cap 806.

According to another aspect, the invention can pertain to an ear tip foruse with a headphone. The ear tip can include a deformable outer memberand is suitable for in-ear operation. The deformable outer memberenables the ear tip to readily conform to a user's ear. The ear tip canalso include an inner member to structurally support the outer memberand to facilitate attachment to a headphone.

The ear tip can, for example, be used with the headphones discussedabove. For example, the ear tip can be removably attached to a headphonesuch as illustrated in FIG. 1A. In one embodiment, the ear tips are softand deformable. The ear tips can be used in-ear. Since the ear tips canreadily deform, the ear tips can operate to substantially seal against auser's ear. For increased comfort, the ear tips can be provided indifferent sizes to accommodate variation in user ear sizes. The colorand translucency of the ear tips can also vary. In addition, thematerials used to form ear tips may vary.

An ear tip can be formed from an elastomer, which is a polymer with theproperty of elasticity. For example, the ear tip can be formed, in wholeor in part, of silicone or silicone rubber. Generally, an ear tip may beformed from any suitable material which is capable of providing a sealwith a surface of a human ear. An ear tip may be formed from materialsincluding, but not limited to including, polyurethane (PU) foam, PU foamwith a silicone skin, silicone gel with a silicone rubber skin, PU foamwith a PU skin, silicone foam, or a thermoplastic (TPE) foam. In oneembodiment, any relatively slow-rebounding material which may bedeformed and then expand to conform to an original geometry may be usedto form at least part of an ear tip.

Materials used to form an ear tip may also be treated to improvedurability and/or cosmetic appearance. By way of example, PU foam may bechemically treated to reduce the number of visible surface pores andsurface wrinkles. Alternatively, an outer later of material can beprovided over the PU form to provide desired characteristics. In oneembodiment, a silicone skin can be formed in a desired configuration foran ear tip and then an internally cavity can be filled with PU or PUfoam. In another embodiment, a PU foam may have a silicone skin moldedthereon, sprayed thereon, or otherwise applied thereon to provide asmooth cosmetic appearance. Hence, a cosmetic appearance may be createdby treating a material from which an ear tip is formed, or a cosmeticappearance may be created by providing a layer, e.g., a layer ofcosmetically appealing material, over the material from which an ear tipis formed.

FIGS. 9A-9E are views of an ear tip 900 according to one embodiment ofthe invention. FIG. 9A is a front perspective view of the ear tip 900,FIG. 9B is a rear perspective view of the ear tip 900, and FIG. 9C is aside perspective view of the ear tip 900.

The ear tip 900 includes an outer structure 902 and an inner structure904. The ear tip 900 also has a top opening 906 provided at a frontsurface 908 of the ear tip 900. The top opening 906 serves as an openingfor audio sound (emitted from a headphone) to be directed into a user'sear canal. The ear phone 900 also has a bottom opening 910 at a rearsurface 912. At the rear surface 912, a bottom edge 914 is providedaround the bottom opening 910.

The inner structure 904 is covered by the outer structure 902. The outerstructure 902 is adhered to or integral with the inner structure 904 atthe front surface 908. The outer structure 902 extends over and aroundthe inner structure 902 but remains open at the bottom opening 910 atthe rear surface 912. Behind the front surface 908, the outer structure902 may be spaced apart from the inner structure 904.

Alternatively, the outer structure 902 may be formed from a membranecomponent 902 a and a solid component 902 b. The solid component 902 ais arranged to be a slow-rebounding component that expands and conformsto a shape, e.g., a shape of an ear cavity in which the ear tip 900 isinserted, after being compressed. Outer structure 902 may be readilydeformed, as for example by pressure applied using fingers. For example,in use, the ear tip 900 will be inserted into or adjacent a user's earcanal and the outer structure 902 can readily deform to substantiallyseal against a user's ear. In particular, the solid component 902 b maydeform to substantially seal against a user's ear.

In one embodiment, the outer structure 902 can include a cosmeticsurface, which can be the exterior surface of the outer structure 902.The cosmetic surface may be, in one embodiment, a silicone skin that issubstantially bonded to an underlying material such as silicone gel,silicone foam, or PU foam. Hence, the outer structure 902 may include afirst pliable material that may conform to the shape of an ear cavity,as well as a second pliable material that essentially forms a cosmeticsurface. The second pliable material may cooperate with the firstpliable material to conform to the shape of an ear cavity. In oneembodiment, the outer structure 902 may effectively include two layers,namely a structural layer and a cosmetic layer.

Membrane component 902 a may be deformed, and is formed fromsubstantially the same material, or materials, used to form solidcomponent 902 b. Membrane component 902 a is arranged such that whileouter structure 902 forms a substantially undercut sphere with a“filled” portion, where solid component 902 b is effectively the filledportion, membrane component 902 a forms an “unfilled” portion such thatan air may effectively fill portions of outer structure 902.

FIG. 9D is a side view of the ear tip 900 according to one embodiment ofthe invention. The configuration of the outer structure 902 according toone embodiment of the invention is illustrated in FIG. 9D. According tothe embodiment illustrated in FIG. 9D, the ear tip 900 can have a height(H) of 10.48 mm, the width (W1) (diameter) of the front surface 908 canbe 4.75 mm, the width (W2) (diameter) of the rear surface 912 can be10.01 mm. A fill height (F), which corresponds to a height of the solidcomponent 902 b of outer structure 902 is generally less than the height(H). The fill height (F) may extend slightly above the widest portion ofear tip 900, as shown, although it should be appreciated that the fillheight (F) may generally be any height that is less than the height (H).

FIG. 9E is a cross-sectional view of the ear tip 900 according to oneembodiment of the invention. The configuration of the inner structure904 according to one embodiment of the invention is illustrated in FIG.9E. The inner structure 904 can be cylindrical, so as to have a tubularconfiguration. The top of the inner structure 904 adheres to or isintegral with the top region of the outer structure 902 at the frontsurface 908. Additionally, the internal configuration of the innerstructure 904 can include one or more attachment features 916 thatfacilitates attachment of the inner structure 904 of the ear tip to aheadphone. For example, the internal configuration of the innerstructure 904 includes at least one recess that can serve as anattachment feature 916. According to the embodiment illustrated in FIG.9E, the inner structure 904 can have a total height (h1) of 6.66 mm, adistance d1 from the front surface 908 to the start of the attachmentfeature 916 is 2.00 mm, the height (h2) of the attachment feature 916(recess) is 1.55 mm, the width (w1) (diameter) of the top opening 906 is2.40 mm, the width (w2) at the attachment feature 916 is 3.99 mm, andthe width (w3) at the lower portion of the inner structure 904 is 3.61mm. The fill height (F), as shown in FIG. 9D, may be greater than orapproximately equal to the total height (h1). In one embodiment, thesolid component 902 b may be configured such that the fill height (F)that is approximately equal to the total height (h1) where the solidcomponent 902 b substantially contacts the internal structure 904, andhave a larger fill height (F) at an interface with the membranecomponent 902 a.

In one embodiment, the hardness of the inner structure 904 and the outerstructure 902 are configured differently. For example, the innerstructure 904 can have a greater hardness that the outer structure 902.In other words, in such an example, the outer structure 902 can besofter than the inner structure 904.

Durometer is one of several ways to indicate the hardness of a material,defined as the material's resistance to permanent indentation. The termdurometer is often used to refer to the measurement, as well as theinstrument itself. Durometer is typically used as a measure of hardnessin polymers, elastomers and rubbers. In one implementation, according toa durometer measurement, the durometer of the inner structure 904 can besixty (60), and the durometer of the outer structure 902 can be forty(40).

FIGS. 10A-10E are views of an ear tip 1000 according to one embodimentof the invention. FIGS. 10A-10E are views of an ear tip 1000 accordingto one embodiment of the invention. FIG. 10A is a front perspective viewof the ear tip 1000, FIG. 10B is a rear perspective view of the ear tip1000, and FIG. 100 is a side perspective view of the ear tip 1000. Theear tip 1000 is smaller than the ear tip 900 illustrated in FIGS. 9A-9E.

The ear tip 1000 includes an outer structure 1002 and an inner structure1004. The ear tip 1000 also has a top opening 1006 provided at a frontsurface 1008 of the ear tip 1000. The top opening 1006 serves as anopening for audio sound (emitted from a headphone) to be directed into auser's ear canal. The ear phone 1000 also has a bottom opening 1010 at arear surface 1012. At the rear surface 1012, a bottom edge 1014 isprovided around the bottom opening 1010.

The inner structure 1004 in contact with the outer structure 1002. Theouter structure 1002 is adhered to or integral with the inner structure1004 at the front surface 1008, and substantially along side surfaces ofinner structure 1004. The outer structure is arranged to be readilydeformed. For example, in use, the ear tip 1000 will be inserted into oradjacent a user's ear canal and the outer structure 1002 can readilydeform to substantially seal against a user's ear.

FIG. 10D is a side view of the ear tip 1000 according to one embodimentof the invention. The configuration of the outer structure 1002according to one embodiment of the invention is illustrated in FIG. 10D.According to the embodiment illustrated in FIG. 10D, the ear tip 1000can have a height (H) of 9.58 mm, the width (W1) (diameter) of the frontsurface 1008 can be 4.48 mm, the width (W2) (diameter) of the rearsurface 1012 can be 10.01 mm.

FIG. 10E is a cross-sectional view of the ear tip 1000 according to oneembodiment of the invention. The configuration of the inner structure1004 according to one embodiment of the invention is illustrated in FIG.10E. The inner structure 1004 can be cylindrical, so as to have atubular configuration. The top of the inner structure 1004 adheres to oris integral with the top region of the outer structure 1002 at the frontsurface 1008. The sides of the inner structure 1004 also adhere to theouter structure 1002. Additionally, the internal configuration of theinner structure 1004 can include one or more attachment features 1016that facilitates attachment of the inner structure 1004 of the ear tipto a headphone. For example, the internal configuration of the innerstructure 1004 includes at least one recess that can serve as anattachment feature 1016. According to the embodiment illustrated in FIG.10E, the inner structure 1004 can have a total height (h1) of 5.76 mm, adistance d1 from the front surface 1008 to the start of the attachmentfeature 1016 is 1.10 mm, the height (h2) of the attachment feature 1016(recess) is 1.55 mm, the width (w1) (diameter) of the top opening 1006is 2.41 mm, the width (w2) at the attachment feature 1016 is 3.99 mm,and the width (w3) at the lower portion of the inner structure 1004 is3.61 mm.

In one embodiment, the hardness of the inner structure 1004 and theouter structure 1002 are configured differently. For example, the innerstructure 1004 can have a greater hardness that the outer structure1002. In other words, in such an example, the outer structure 1002 canbe softer than the inner structure 1004. The outer structure 1002 may beformed from a deformable material, such as a slow-rebounding material.In one implementation, according to a durometer measurement, thedurometer of the inner structure 1004 can be about fifty (50), and thedurometer of the outer structure 1002 can be about thirty (30).

FIGS. 11A-11E are views of an ear tip 1100 according to one embodimentof the invention. FIGS. 11A-11E are views of an ear tip 1100 accordingto one embodiment of the invention. FIG. 11A is a front perspective viewof the ear tip 1100, FIG. 11B is a rear perspective view of the ear tip1100, and FIG. 11C is a side perspective view of the ear tip 1100. Theear tip 1100 is larger than the ear tip 900 illustrated in FIGS. 9A-9E.

The ear tip 1100 includes an outer structure 1102 and an inner structure1104. The ear tip 1100 also has a top opening 1106 provided at a frontsurface 1108 of the ear tip 1100. The top opening 1106 serves as anopening for audio sound (emitted from a headphone) to be directed into auser's ear canal. The ear tip 1100 also has a bottom opening 1110 at arear surface 1112. At the rear surface 1112, a bottom edge 1114 isprovided around the bottom opening 1110.

The inner structure 1104 is in contact with the outer structure 1102.The outer structure 1102 is adhered to or integral with the innerstructure 1104 at the front surface 1108, as well as along the sides ofinner structure 1104. The outer structure 1102 extends around the innerstructure 1102 but remains substantially open at the bottom opening 1110at the rear surface 1112. In use, the ear tip 1100 will be inserted intoor adjacent a user's ear canal and the outer structure 1102 can readilydeform to substantially seal against a user's ear.

FIG. 11D is a side view of the ear tip 1100 according to one embodimentof the invention. The configuration of the outer structure 1102according to one embodiment of the invention is illustrated in FIG. 11D.According to the embodiment illustrated in FIG. 11D, the ear tip 1100can have a height (H) of 11.53 mm, the width (W1) (diameter) of thefront surface 1108 can be 4.76 mm, the width (W2) (diameter) of the rearsurface 1112 can be 10.01 mm.

FIG. 11E is a cross-sectional view of the ear tip 1100 according to oneembodiment of the invention. The configuration of the inner structure1104 according to one embodiment of the invention is illustrated in FIG.11E. The inner structure 1104 can be cylindrical, so as to have atubular configuration. The top of the inner structure 1104 may adhere toor may be integral with the top region of the outer structure 1102 atthe front surface 1108. Additionally, the internal configuration of theinner structure 1104 can include one or more attachment features 1116that facilitates attachment of the inner structure 1104 of the ear tipto a headphone. For example, the internal configuration of the innerstructure 1104 includes at least one recess that can serve as anattachment feature 1116. Sides of the inner structure 1104 may also beadhered to outer structure 1102. According to the embodiment illustratedin FIG. 11E, the inner structure 1104 can have a total height (h1) of7.71 mm, a distance d1 from the front surface 1108 to the start of theattachment feature 1116 is 3.05 mm, the height (h2) of the attachmentfeature 1116 (recess) is 1.55 mm, the width (w1) (diameter) of the topopening 1106 is 2.40 mm, the width (w2) at the attachment feature 1116is 3.99 mm, and the width (w3) at the lower portion of the innerstructure 1104 is 3.61 mm.

In one embodiment, the hardness of the inner structure 1104 and theouter structure 1102 are configured differently. For example, the innerstructure 1104 can have a greater hardness that the outer structure1102. In other words, in such an example, the outer structure 1102 canbe softer than the inner structure 1104. In one implementation,according to a durometer measurement, the durometer of the innerstructure 1104 can be about sixty (60), and the durometer of the outerstructure 1002 can be about forty (40).

Various materials used to form an ear tip may generally be processed toprovide desirable aesthetic, or cosmetic, properties. For example, a PUfoam with a relatively smooth exterior surface may be more pleasing tothe eye than other PU foams. A relatively smooth exterior surface may beone with relatively few surface bubbles and/or relatively few wrinkles.To control the surface bubbles or, more generally, the pore size of thePU foam, the ratio of components of the PU foam may be changed. Forexample, the amount of silicon surfactants in the PU foam may be alteredto substantially control the pore size associated with the PU foam.

In one embodiment, an inner structure of an ear tip may be formed from asolid PU, with PU foam overmolded onto the solid PU to form an outerstructure. The PU foam may be treated to substantially minimize surfacepores and wrinkles.

An ear tip may include an outer structure formed from a PU foam that iscoated with a PU skin. Solid PU may be sprayed in a mold, for example,prior to filling the mold with PU foam, thereby resulting in a PU skinbeing formed on a PU structure. The PU skin may improve mechanical andchemical resistance, and also the cosmetic qualities of the ear tip.

A silicone skin or surface may be added to the surface of PU foam toimprove the cosmetic qualities of an ear tip formed from the PU foam, aswell as to enhance the durability of the PU foam. The silicone skin maybe molded (e.g., over molded) onto the PU foam, or sprayed onto the PUfoam. Alternatively, the PU form may be molded (e.g., over molded) ontothe silicone skin. The silicone skin may also be applied by dipping thePU foam into silicone. A plasma or chemical process may be utilized toenable the silicone to effectively stick to the PU foam. A PU foam witha silicone skin generally has desirable chemical, mechanical, andenvironmental properties.

A relatively slow-rebounding ear tip may be formed from a silicone foamor gel that may be contained by a silicone rubber skin. Such a siliconerubber skin may be overmolded onto the silicone foam or gel. It shouldbe appreciated that while the volume of PU foam can be pressed and thenrebound, the volume of a silicone foam or gel may effectively bedisplaced. The silicone rubber skin may be provided for cosmeticpurposes and/or for durability. In some instances, a silicone foam mayalso be used without a silicone rubber skin to form an ear tip.

FIG. 12 is a flow diagram of an ear tip formation process 1200 accordingto one embodiment of the invention. The ear tip formation process 1200can, for example, be used to form ear tips utilized by headphones. Theear tips being formed can, for example, be the ear tips 900, 1000 or1100 illustrated in FIGS. 9A-11E.

The ear tip formation process 1200 can initially configure 1202 top andbottom molding plates. The molding plates are associated with a moldingstation (e.g., an injection molding station) of an assembly area. Themolding plates can be custom formed for molding ear tips in accordancewith the invention. The top and bottom molding plates can form a firstmold. Next, an inner structure can be compression molded 1204 using afirst moldable material injected into the first mold. As an example, thefirst mobile material can be silicone. Once molded, the formed innerstructure can be cured 1206. The inner structure can be cured 1206 usingradiation, such as heat or UV light, and/or time.

Next, the molding station can be reconfigured 1208 by replacing one ofthe top and bottom molding plates. The new combination of molding platescan form a second mold. For example, the top molding plate utilized inthe molding of the inner structure can be removed and replaced with adifferent top molding plate. In this case, the new top molding platefacilitates creation of an outer structure. The top and bottom moldingplates may be sprayed or otherwise coated, in one embodiment, with asilicone or PU material to facilitate the creation of an exterior skinon an outer structure. After the molding station has been reconfigured1208, an outer structure can be compression molded 1210 using a secondmoldable material injected into the second mold. As an example, thesecond moldable material can also be silicone such as a silicone foam,or the second moldable material can be a PU foam or a TPE foam. In oneembodiment, the deformability of the second moldable material issignificantly greater than that of the first moldable material. When theouter structure is compression molded 1210 it is integrally formed ontoan upper portion of the inner structure. Once molded, the formed outerstructure can be cured 1212. The combination of the inner structure andthe outer structure results in an ear tip. Since the molding platetypically forms a plurality of structures at one time, the ear tipformation process 1200 can concurrently produce a plurality of ear tips.After the formed outer structure has been cured 1212, the formed ear tipor tips can be removed 1214 from the molding plates. Following the block1214, the ear tip formation process 1200 can end.

In some instances, separate molding processes may be used to form anouter structure, as for example when the outer structure is formed froma first material and a second material overmolded onto the firstmaterial. FIG. 13 is a flow diagram of an ear tip formation process 1300which includes overmolding materials to form an outer structure of theear tip according to another embodiment of the invention. The ear tipformation process 1300 can, for example, be used to form ear tipsutilized by headphones. The ear tips being formed can, for example, bethe ear tips 900, 1000, 1100 or 1500 illustrated in FIGS. 9A-11E and 15.However, the ear tips are not limited to being those illustrated inFIGS. 9A-11E and 15.

The ear tip formation process 1300 can initially configure 1302 top andbottom molding plates. The molding plates are associated with a moldingstation (e.g., an injection molding station) of an assembly area. Themolding plates can be custom formed for molding ear tips in accordancewith the invention. The top and bottom molding plates can form a firstmold. Next, an inner structure can be compression molded 1304 using afirst moldable material injected into the first mold. As an example, thefirst mobile material can be silicone. Once molded, the formed innerstructure can be cured 1306. The inner structure can be cured 1306 usingradiation, such as heat or UV light, and/or time.

Next, the molding station can be reconfigured 1308 by replacing one ofthe top and bottom molding plates. The new combination of molding platescan form a second mold. For example, the top molding plate utilized inthe molding of the inner structure can be removed and replaced with adifferent top molding plate. In this case, the new top molding platefacilitates creation of an outer structure. After the molding stationhas been reconfigured 1308, a portion of an outer structure can becompression molded 1310 using a second moldable material injected intothe second mold. As an example, the second moldable material can also besilicone such as a silicone foam, or the second moldable material can bea PU foam or a TPE foam. In one embodiment, the deformability of thesecond moldable material is significantly greater than that of the firstmoldable material. When the portion of the outer structure iscompression molded 1310, it is integrally formed onto an upper portionof the inner structure. Once molded, the formed portion of the outerstructure can be cured 1311.

The molding station can be reconfigured 1312 by replacing at least oneof the top and bottom molding plates. The plate or plates may bereconfigured such that another portion of the outer structure may becompression molded. For example, a silicone skin may be formed over asilicone foam portion of the outer structure. Thus, a portion of theouter structure can be compression molded 1313, e.g., overmolded, usinga third moldable material injected into a third mold. Once molded, theouter structure can be cured 1314.

The combination of the inner structure and the portions of the outerstructure results in an ear tip. Since the molding plate typically formsa plurality of structures at one time, the ear tip formation process1300 can concurrently produce a plurality of ear tips. After the formedouter structure has been cured 1314, the formed ear tip or tips can beremoved 1315 from the molding plates. Following the block 1315, the eartip formation process 1300 can end.

As previously mentioned, a coating such as a silicone skin may beapplied to an outer structure of an ear tip through a dipping orspraying process. FIG. 14 is a flow diagram of an ear tip formationprocess 1400 that includes applying a coating to an outer structureaccording to one embodiment of the invention. The ear tip formationprocess 1400 can, for example, be used to form ear tips utilized byheadphones. The ear tips being formed can, for example, be the ear tips900, 1000, 1100 or 1500 illustrated in FIGS. 9A-11E and 15.

The ear tip formation process 1400 can initially configure 1402 top andbottom molding plates. The molding plates are associated with a moldingstation (e.g., an injection molding station) of an assembly area. Themolding plates can be custom formed for molding ear tips in accordancewith the invention. The top and bottom molding plates can form a firstmold. Next, an inner structure can be compression molded 1404 using afirst moldable material injected into the first mold. As an example, thefirst mobile material can be silicone. Once molded, the formed innerstructure can be cured 1406. The inner structure can be cured 1406 usingradiation, such as heat or UV light, and/or time.

Next, the molding station can be reconfigured 1408 by replacing one orboth of the top and bottom molding plates. The new combination ofmolding plates can form a second mold. For example, the top moldingplate utilized in the molding of the inner structure can be removed andreplaced with a different top molding plate. In this case, the new topmolding plate facilitates creation of an outer structure. After themolding station has been reconfigured 1408, an outer structure can becompression molded 1410 using a second moldable material injected intothe second mold. As an example, the second moldable material can also besilicone such as a silicone foam, or the second moldable material can bea PU foam or a TPE foam. In one embodiment, the deformability of thesecond moldable material is significantly greater than that of the firstmoldable material. When the outer structure is compression molded 1410it is integrally formed onto an upper portion of the inner structure.

Once molded, the formed outer structure can be cured 1411. Thecombination of the inner structure and the outer structure results in anear tip. Since the molding plate typically forms a plurality ofstructures at one time, the ear tip formation process 1400 canconcurrently produce a plurality of ear tips. After the formed outerstructure has been cured 1412, the formed ear tip or tips can be removed1415 from the molding plates. An outer coating can be applied 1416 toear tips. That is, a cosmetic surface can be applied to ear tips.Applying an outer coating may include, but is not limited to including,spraying an outer coating material onto the outer structure or dippingthe outer structure into an outer coating material. By way of example, asilicone coating may be applied to a PU foam. Following the block 1416,the ear tip formation process 1400 can end.

As previously mentioned, an outer structure of an ear tip may be formedfrom a material that is at least partially covered (e.g., coated) withanother material. With reference to FIG. 15, an ear tip with an outerstructure that is formed from a material, e.g., PU foam, that is covered(e.g., coated) by another material, e.g., a silicone film, is shown inaccordance with an embodiment of the invention. An ear tip 1500 includesan inner structure 1504 that is covered by an outer structure 1502. Theouter structure 1502 is adhered to or integral with the inner structure1504 at a front surface 1508, as well as along sides of inner structure1504. The outer structure 1502 extends over and around the innerstructure 1504 but remains open at a bottom opening 1510 at a rearsurface 1512.

The outer structure 1502 includes a first material 1502 a and a secondmaterial 1502 b. The first material 1502 a may be, in one embodiment, aPU foam while the second material 1502 b may be silicone. The secondmaterial 1502 b may form a cosmetic surface of outer structure 1502. Ingeneral, the second material 1502 b may form at least an exteriorsurface of the outer structure 1502.

In the ear tip formation processing 1200 the inner structure can beformed before the outer structure. However, in alternative embodiment,the outer structure can be formed before the inner structure. Thisalternative approach can yield improved durability and/or cosmeticappearance.

FIG. 16 is a flow diagram of an ear tip formation process 1600 accordingto one embodiment of the invention. The ear tip formation process 1600can, for example, be used to form ear tips utilized by headphones. Theear tips being formed can, for example, be the ear tips 900, 1000, 1100or 1500 illustrated in FIGS. 9A-11E and 15.

The ear tip formation process 1600 can initially configure 1602 top andbottom molding plates. The molding plates are associated with a moldingstation (e.g., an injection molding station) of an assembly area. Themolding plates can be custom formed for molding ear tips in accordancewith the invention. The top and bottom molding plates can form a firstmold. Next, an outer structure can be compression molded 1604 using afirst moldable material injected into the first mold. As an example, thefirst mobile material can be silicone. Once molded, the formed outerstructure can be cured 1606. The outer structure can be cured 1606 usingradiation, such as heat or UV light, and/or time.

Next, the molding station can be reconfigured 1608 by replacing one ofthe top and bottom molding plates. The new combination of molding platescan form a second mold. For example, the top molding plate utilized inthe molding of the outer structure can be removed and replaced with adifferent top molding plate. In this case, the new top molding platefacilitates creation of an inner structure. The formed outer structureforms an inner cavity into which the inner structure is to be formed.The exposed inner surface of the formed outer structure may be sprayedor otherwise coated, in one embodiment, with a primer to assist withadhesion to the inner surface of the inner cavity of the outerstructure. For example, if the first moldable material is silicone,which has low surface energy, a primer coating can assist with adhesionto other materials. On example of a suitable primer may be Silane.Silane is a chemical compound with chemical formula SiH₄.

After the molding station has been reconfigured 1608 and any primerapplied, an inner structure can be compression molded 1610 using asecond moldable material injected into the second mold. As an example,the second moldable material can also be silicone such as silicone foam,or the second moldable material can be a PU foam or a TPE foam. In oneembodiment, the deformability of the first moldable material issignificantly greater than that of the second moldable material. Whenthe inner structure is compression molded 1610 it is integrally formedwithin the inner cavity of the outer surface. Once molded, the formedouter structure can be cured 1612. The combination of the innerstructure and the outer structure results in an ear tip. Since themolding plate typically forms a plurality of structures at one time, theear tip formation process 1600 can concurrently produce a plurality ofear tips. After the formed inner structure has been cured 1612, theformed ear tip or tips can be removed 1614 from the molding plates.Following the block 1614, the ear tip formation process 1600 can end.

In another embodiment, instead of applying a primer to the inner surfaceof the outer structure, corona processing can by induced on the innersurface of the outer structure so that adhesion characteristics can beimproved. The corona processing acts as an electrically induced surfacetreatment. In generally, a corona discharge is an electrical dischargebrought on by the ionization of a fluid surrounding a conductor, whichoccurs when the potential gradient (the strength of the electric field)exceeds a certain value, but conditions are insufficient to causecomplete electrical breakdown or arcing.

In one embodiment of the ear tip formation process 1600, the formedouter structure can be highly durable and elastic such that it can beinverted. The application of the primer can be performed in mold or outof mold. In one embodiment, if may be advantageous to invert the innersurface of the formed outer structure so that it can be coated orsprayed with the primer or altered by corona processing. Thereafter, theouter structure can be uninverted.

In another embodiment, an inner structure for an ear tip cansubstantially extend through the height of the ear tip. The extendedinner structure can improve tear strength for an open end of the eartip. The extended inner structure can also reduce likelihood ofdelamination between the material of the inner structure and thematerial for the outer structure. As noted above, the material used forthe inner structure and the outer structure can vary depending onimplementation. In one example, the material for the inner structure isa solid PU, and the material for the outer material is PU foam. Inanother example, the material for the inner structure is silicone, andthe material for the outer structure is PU foam. The material for theouter structure can be over-molded onto the material for the innerstructure, or the material for the inner material can be over-moldedonto the material for the outer material.

FIG. 17 illustrates an ear tip 1700 with an extended inner structureaccording to one embodiment of the invention. The ear tip 1700 has anouter structure 1702. The outer structure 1702 is adhered to or integralwith the inner structure 1704 at a front surface 1708, as well as alongsides of inner structure 1704. The outer structure 1702 extends over andaround the inner structure 1704 but remains open at a bottom opening1710 at a rear surface 1712.

The inner structure 1704 has a lower portion 1704 a and an upper portion1704 b. The lower portion 1704 a of the inner structure 1704 is providedat a lower portion of the ear tip 1700, while the upper portion 1704 bof the inner structure 1704 is provided at an upper portion of the eartip 1700. As compared to other embodiments where the inner structureincludes only the lower portion 1704 a adjacent the lower portion of theear tip 1700, in this embodiment the inner structure 1704 extendsthrough the ear tip 1700. The addition of the upper portion 1704 b canprovide the ear tip 1700 with greater durability (e.g., increased tearstrength).

The outer structure 1702 includes a first material 1702 a. The firstmaterial 702 a may be, in one embodiment, a PU foam. Optionally, such asillustrated in FIG. 15, the outer structure 1702 can also include asecond material (e.g., second material 1502 b). The second material forthe outer structure 1702 may, for example, be silicone. The secondmaterial for the outer structure 1702, if provided, may form a cosmeticsurface of outer structure 1702. In general, although not illustrated inFIG. 17, the second material for the outer structure 1702 may form atleast an exterior surface of the outer structure 1702. The ear tip 1700can be formed with a molding process that forms the inner structure 1704before the outer structure 1702, or the ear tip 1700 can be formed witha molding process that forms the inner structure 1704 after the outerstructure 1702.

FIG. 18 is a cross-sectional view of an ear tip 1800 with an extendedinner structure 1802 according to one embodiment of the invention. Theear tip 1800 can be formed from an inner member 1802 and an outer member1804. In this exemplary embodiment, the inner member 1802 can be a solidurethane elastomer (e.g. solid PU) that extends substantially entirelythrough the ear tip 1800, which can serve to improve tear strength. Theouter member 1804 can be an urethane foam (e.g., PU foam).

FIG. 19A is a rear view, FIG. 19B is a side view, and FIG. 19C is across-sectional view of an ear tip 1900 according to one embodiment. Theear tip 1900, like the ear tip 1700 illustrated in FIG. 17, has anextended inner structure.

The ear tip 1900 has an outer structure 1902 and an inner structure1904. The configuration (e.g., shape) of the outer structure 1902according to one embodiment is illustrated in FIG. 19B, which can bereferred as a spherical. Here, the sides of the outer structure 1902 arerounded or curved. According to the embodiment illustrated in FIG. 19B,the ear tip 1900 can have a height (H) of 11.53 mm, the width (W1)(diameter) of the front surface 1108 can be 4.76 mm, the width (W2)(diameter) of the rear surface 1914 can be 10.01 mm. However, it shouldbe understood that these sizes are exemplary and that the sizes varywith implementation. Often, the ear tips 1900 are formed in varioussizes (e.g., small, medium and large) to accommodate user's withdifferent size ears.

In FIG. 19C, the configuration of the inner structure 1904 according toone embodiment is illustrated. The inner structure 1904 can be formedwith a first compression molding process, and the outer structure 1902can be formed with a second compression molding process. The innerstructure 1904 can be cylindrical, so as to have a tubularconfiguration. The front region of the inner structure 1904 provides anopening 1906 through which audio sound can be provided to a user's ear.The front region of the inner structure 1904 may adhere to or may beintegral with the front region of the outer structure 1902 at a frontsurface 1908. Additionally, the internal configuration of the innerstructure 1904 can include one or more attachment features thatfacilitate attachment of the inner structure 1904 of the ear tip 1900 toa headphone. For example, the internal configuration of the innerstructure 1904 can include at least one recess 1909 that can serve as anattachment feature. Outer sides of the inner structure 1904 may also beadhered to outer structure 1902. In one embodiment, the hardness of theinner structure 1904 and the outer structure 1902 are configureddifferently. For example, the inner structure 1904 can have a greaterhardness that the outer structure 1902. In other words, in such anexample, the outer structure 1902 can be softer than the inner structure1904. In one implementation, according to a durometer measurement, thedurometer of the inner structure 1904 can be about sixty (60), and thedurometer of the outer structure 1902 can be about forty (40). The eartip 1900 also has a rear region 1910. The rear region 1910 can providean opening 1912 for receiving an ear tip. The rear portion of the innerstructure 1904 may adhere to or may be integral with the rear region ofthe outer structure 1902 at the rear region 1910 of the ear tip 1900.More generally, in one embodiment, some or all of the outer sides of theinner structure 1904 can adhere to or be integral with some or all ofthe inner sides of the outer structure 1902.

FIGS. 20A and 20B illustrated a flow diagram of an ear tip formationprocess 2000 according to one embodiment. The ear tip formation process2000 can, for example, be used to form ear tips utilized by headphones.The ear tips being formed can, for example, be the ear tips 1800 or 1900illustrated in FIGS. 18-19C.

The ear tip formation process 2000 can initially form 2002 an innerstructure for an ear tip being formed. The inner ear structure for theear tip can be formed in a variety of different ways, including by amolding process.

After obtaining the inner structure, the ear tip formation process 2000can form an outer structure for the ear tip. The outer structure can beformed using molding plates associated with a molding station (e.g., aninjection molding station) at an assembly area. The molding plates canbe custom formed for molding ear tips in accordance with the invention.To form the outer structure for the ear tip, a top mold having at leastone protrusion and a bottom mold having at least one ear tip cavity canbe provided 2004. A sheet of a first material can be placed 2006 overthe ear tip cavity in the bottom mold. The sheet can be a thin sheet ofpolyurethane (e.g., thermoset polyurethane (TPU). For example, the sheetcan be a polyurethane sheet (or film) with a thickness of 0.1 mm. Moregenerally, the sheet has a thickness of 0.5-5 mm and can be formed of anelastomer.

Next, a quantity of a second material can be deposited 2008 on the sheetand adjacent the ear tip cavity in the bottom mold. The second materialis used in forming the outer structure for the ear tip. For example, thesecond material can be a polyurethane form. Next, the sheet and thesecond material deposited there on can be drawn 2010 into the cavity.For example, in one implementation, a vacuum can be induced to draw 2010the sheet as well as at least a portion of the deposited second materialinto the cavity. In one implementation, the bottom mold it is a porousmetal mold (e.g., porous aluminum or steel), such that when a vacuum isimposed, a pressure difference can be formed to draw the sheet and theat least a portion of the deposited second material into the cavity.

Thereafter, the inner structure that was previously formed 2002 can beplaced 2012 onto the protrusion of the top mold. The protrusion of thetop mold can be designed to receive the inner structure for the ear tipbeing formed. The top mold and the bottom mold can then be coupled 2014together with the protrusion being inserted into the cavity. At thispoint, the second material can be cured 2016. The curing can befacilitated through heat, such as through heating of one or more of themolds.

After the second material has been cured 2016, the top mold can beremoved 2018. Any excess material, namely, the second material, can alsobe removed 2020. At this point, the ear tip has been formed and can thenbe removed 2022 from the bottom mold. In one implementation, airpressure can be applied to the porous bottom mold to cause the formedear tip to dislodge from the bottom mold. Following the block 2022, theear tip formation process 2000 can end.

FIGS. 21A-21G are cross-sectional diagrams illustrating ear tipformation according to one embodiment of the invention.

FIG. 21A illustrates a bottom mold 2100 according to a first stage ofthe ear tip formation. The bottom mold 2100 includes a cavity 2102. Thecavity 2102 is configured to have a shape suitable for formation of anouter member of the ear tip. In one embodiment, the bottom mold 2100 canalso include a plurality of holes 2104. In other words, the bottom moldcan be referred to as a porous mold, and/or the cavity 2102 can bereferred to as a porous cavity. In addition, an elastomer film 2106(e.g., polyurethane) is provided for formation of the ear tip. Theelastomer film 2106 can provide an outer surface for the ear tip beingformed.

FIG. 21B illustrates the bottom mold 2100 according to a second stage ofthe ear tip formation. In the second stage, the elastomer film 2106 isplaced over the cavity 2102. In doing so, the elastomer film 2106extends beyond simply covering the cavity 2102. Additionally, a quantityof viscous outer material 2108 (e.g., polyurethane foam) can bedeposited on the elastomer film 2106 over the cavity 2102.

Then, a vacuum pressure can be applied to the bottom mold 2100 (or atleast the cavity 2102 portion thereof). The vacuum pressure can beapplied to the cavity 2102 since the bottom mold 2100 (or the cavity2102) is porous. As a result, the viscous outer material 2108 is drawninto the cavity 2102.

FIG. 21C illustrates the bottom mold 2100 according to a third stage ofthe ear tip formation. Here, the elastomer film 2106 and the viscousouter material 2108 previously over the cavity 2102 are now within thecavity 2102. Through application of heat, the viscous outer material2108 can expand to fill the cavity 2102.

FIG. 21D illustrates a top mold 2110 and the bottom mold 2100 accordingto a fourth stage of the ear tip formation. The top mold 2110 caninclude a protrusion 2112 configured to receive an inner member 2114(e.g., inner core element for the ear tip). Typically, the inner member2114 is separately molded and thus available to be provided on theprotrusion 2112. In one implementation, the top mold 2110 can be formedof steel.

FIG. 2E illustrates formation of the ear tip according to a fifth stageof the ear tip formation. To form the ear tip, the inner member 2114 isthen shaped and connected to the inner member 2114 by bring the top mold2110 and the bottom mold 2100 together. As shown in FIG. 2E, when thetop mold 2110 and the bottom mold 2100 are brought together, theprotrusion 2112 of the top mold 2110, having the inner member 2114provided thereon, is inserted within the cavity 2102. Consequently, anouter member 2116 for the ear tip is formed. The outer surface of theouter member 2116 is provided by the viscous outer material 2108conformed against the inner surface of the cavity 2102 via the elastomerfilm 2106. In doing so, the outer member 2116 is attached to the innermember 2114. For example, the outer member 2116 can be molded onto aportion of the inner member 2114. The viscous outer material 2108 can bethen cure or solidify. The top mold 2110 can be separated from thebottom mold 2100.

When the top mold 2110 and the bottom mold 2100 are brought together,some of the viscous outer material 2108 that was drawn into the cavity2102 can be displaced from the cavity 2102. In other words, a portion ofthe viscous outer material 2108 can overflow outward from the cavity2102. The overflowed outer material 2108′ can reside on the top of thebottom mold 2100.

FIG. 21F illustrates formation of the ear tip according to a sixth stageof the ear tip formation. The sixth stage provides for removal ofundesired materials from the ear tip after removing the top mold 2110. Aheated die 2118 can be used to separate the residual or undesiredmaterials from the ear tip that has been formed. For example, theresidual or undesired materials can include any excess portion of theelastomer film 2106 as well as any of the viscous outer material 2108′that displaces from the cavity 2102 to the surface of the bottom mold2000. The heated die 2118 can be brought against the top surface of thebottom mold 2100 adjacent the cavity 2102. The heated die 2118 serves toseparate the formed ear tip from any residual or undesired portions of(i) that portion of the viscous outer material 2108′ that has overflowedonto the top of the bottom surface 2100, and/or (ii) that excess portionof the elastomer film 2106 that remains on the top of the bottom surface2100.

FIG. 21G illustrates formation of the ear tip according to a seventhstage of the ear tip formation in which the ear tip is fully formed.Thereafter, the formed ear tip can be removed from the bottom mold 2100.In one embodiment, to easily remove the formed ear tip from the bottommold 2106, air pressure can be used to push the formed ear tip out ofthe cavity 2102. Since the bottom portion 2100 or at least its cavity2102 has holes, an applied air pressure can be supplied to the cavity2102 to withdraw of the formed ear tip from the cavity 2102, and usuallywithout any damage thereto.

Although the ear tip formation illustrated in FIGS. 21A-21G depictformation of a single ear tip, it should be understood that a pluralityof ear tips can be concurrently formed, such as in a batch. In such casethe elastomer film 2106 can be provide as a sheet of elastomer materialthat extends over the cavities used to form the plurality of ear tipsconcurrently.

The ear tips being formed can, for example, be formed from one or moreelastomers. An ear tip may be formed from materials including, but notlimited to including, polyurethane (PU) foam, PU foam with a siliconeskin, silicone gel with a silicone rubber skin, PU foam with a PU skin,silicone foam, or a thermoplastic (TPE) foam. In the case of embodimentswith an inner structure and an outer structure, the inner structure canbe less compliant, so as to provide more structural support, while theouter structure can be more compliant, so as to adapt to a user's earand provide a comfortable fit. Although the inner structure and theouter structure can be formed of the same material or materials of alike composition, which can facilitate bonding between the innerstructure and the outer structure, it is not necessary that thematerials used for the inner structure and the outer structure be thesame.

In one embodiment, the outer structure can be formed with a gel or foam,such as silicone gel, silicone foam or polyurethane foam. For durabilityand/or cosmetics reasons, exposed portions of the outer structure can becovered. For example, the formed gel or foam of the outer structure thatis exposed can be covered (e.g., by a film or by spray) with silicone,polyurethane or some other material. As another example, a layer ofsilicon can be molded onto the exposed portion of the formed gel or foamof the outer structure.

In another embodiment an ear tip can include a filter for substantiallyblocking foreign matter. An inner structure of an ear tip may include afilter such as a mesh. The filter can, for example, be formed of metal,such as stainless steel, or a polymer, such as nylon.

The various aspects, features, embodiments or implementations of theinvention described above can be used alone or in various combinations.

This application references: (i) U.S. patent application Ser. No.12/124,471, filed May 21, 2008, entitled “INVERTIBLE EAR TIPS FOR AN EARPIECE”, which is hereby incorporated herein by reference; (ii) U.S.patent application Ser. No. 12/205,749, filed Sep. 5, 2008, entitled“EARPHONE WITH REMOVABLE COMPONENT”, which is hereby incorporated hereinby reference; and (iii) U.S. patent application Ser. No. 12/205,748,filed Sep. 5, 2008, entitled “REMOVABLE EAR TIP FOR EARPHONE”, which ishereby incorporated herein by reference.

The many features and advantages of the present invention are apparentfrom the written description. Further, since numerous modifications andchanges will readily occur to those skilled in the art, the inventionshould not be limited to the exact construction and operation asillustrated and described. Hence, all suitable modifications andequivalents may be resorted to as falling within the scope of theinvention.

What is claimed is:
 1. An ear tip for a headphone, comprising: an innerstructure configured to removably attach to the headphone, the innerstructure comprises a top end and a side extending from the top end,wherein an internal surface of the side comprises at least one featureto mechanically secure the inner structure to the headphone; and anouter structure formed at least partially from a deformable material,the outer structure comprising a front surface and a rear surface, andthe outer structure being one of integrally formed with and coupled tothe top end of the inner structure at the front surface and at least aportion of an external surface of the side, wherein the inner structureis operative to structurally support the outer structure; and wherein aplane, which is perpendicular to the direction in which the side extendsfrom the to end, intersects a portion of the at least one feature of theinternal surface of the side and the at least a portion of the externalsurface of the side.
 2. The ear tip as recited in claim 1, wherein theouter structure is softer than the inner structure.
 3. The ear tip asrecited in claim 1, wherein the inner structure is more rigid than theouter structure.
 4. The ear tip as recited in claim 1, wherein the outerstructure extends over and around the inner structure.
 5. The ear tip asrecited in claim 4, wherein the outer structure is spaced apart from theinner structure behind the front surface.
 6. The ear tip as recited inclaim 4, wherein the outer structure is not sealed to a bottom end ofsaid inner structure, and wherein the side extends between the top endand the bottom end.
 7. The ear tip as recited in claim 1, wherein theouter structure comprises: a membrane component; and a solid component.8. The ear tip as recited in claim 7, wherein the membrane componentforms an undercut structure and the solid component integrates themembrane component to the side of the inner structure.
 9. The ear tip asrecited in claim 7, wherein the membrane and solid components are formedfrom the same material or materials.
 10. The ear tip as recited in claim1, wherein the inner structure is formed at least partially from adeformable material, and the inner structure is operative to deform lessthan the outer structure.
 11. The ear tip as recited in claim 1, whereinthe inner structure is an elastomer and the outer structure is anelastomer.
 12. An ear tip for a headphone, comprising: an innerstructure configured to removably attach to the headphone, the innerstructure comprises a top end and a side extending from the top end,wherein an internal surface of the side comprises at least one featureto mechanically secure the inner structure to the headphone; and anouter structure formed at least partially from a deformable material,the outer structure being one of integrally formed with and coupled toat least a portion of an external surface of the side of the innerstructure, wherein the inner structure has a first hardness and theouter structure has a second hardness, the second hardness being lessthan the first hardness; and wherein a plane, which is perpendicular tothe direction in which the side extends from the to end, intersects oneof the at least one feature of the internal surface of the side and theat least a portion of the external surface of the side.
 13. The ear tipas recited in claim 12, wherein the inner and outer structures are madefrom the same material.
 14. The ear tip as recited in claim 13, whereinthe material comprises one selected from the group including silicone,polyurethane, thermoplastic, and a combination thereof.
 15. The ear tipas recited in claim 12, wherein said outer structure comprises silicone.16. The ear tip as recited in claim 15, wherein the silicone comprises asilicone gel or a silicone foam.
 17. A headphone, comprising: aheadphone body comprising front and back bodies, the front bodycomprising a protruding body; and an ear tip comprising: an innerstructure comprising a side of the inner structure extending from a topend of the inner structure, wherein at least a portion of a firstsurface of the side of the inner structure is configured to removablyattach to the protruding body; and an outer structure being one ofintegral with and adhered to at least a portion of a second surface ofthe side of the inner structure, the outer structure comprising amembrane component and a solid component, wherein the solid componentintegrates the membrane component to the inner structure, wherein themembrane and solid components are operative to deform during in-earusage, and wherein a plane, which is perpendicular to the direction inwhich the side extends from the to end, intersects the at least aportion of the first surface of the side and the at least a portion ofthe second surface of the side.
 18. The headphone of claim 17, whereinthe outer structure being one of integral with and adhered to a firstportion of an external surface of the side of the inner structure,wherein an air interface exists between the membrane component and asecond portion of the external surface of the side of the innerstructure, and wherein the membrane component is configured to deformwithin the air interface during in-ear usage.
 19. The headphone of claim17, wherein an internal surface of a portion of the side of the innerstructure comprises at least one feature to mechanically secure theinner structure to the protruding body, and wherein an external surfaceof the portion of the side of the inner structure is coupled to thesolid component.
 20. The headphone of claim 17, wherein the membrane andsolid components are formed from one of the same material and the samematerials.
 21. An ear tip for a headphone, comprising: an innerstructure comprising a side of the inner structure extending from a toend of the inner structure; and an outer structure being one of integralwith and adhered to at least a portion of a surface of the side of theinner structure, the outer structure comprising a membrane component anda solid component, wherein the solid component integrates the membranecomponent to the inner structure, wherein: an inner surface of a portionof the inner structure is configured to attach to the headphone; anouter surface of the portion of the inner structure structurallysupports the outer structure; the outer structure is more compliant thanthe inner structure; and a plane, which is perpendicular to at least oneof the inner surface and the outer surface, intersects the inner surfaceand the outer surface.
 22. The ear tip of claim 21, wherein at least aportion of the outer structure extends over and around at least theportion of the inner structure.
 23. The ear tip of claim 21, wherein theinner surface of the inner structure comprises an attachment featurethat facilitates attachment of the inner structure to the headphone. 24.The ear tip of claim 23, wherein the attachment feature comprises atleast one recess.
 25. The ear tip of claim 23, wherein at least theouter surface of the portion of the inner structure is coupled to theouter structure.
 26. The ear tip of claim 23, wherein at least the outersurface of the portion of the inner structure is adhered to the outerstructure.
 27. The ear tip of claim 21, wherein the inner structureprovides a first end of the ear tip.
 28. The ear tip of claim 27,wherein the outer structure provides a second end of the ear tip that isopposite the first end of the ear tip.
 29. An ear tip for a headphone,comprising: an inner structure; and an outer structure, wherein: atleast a portion of a first surface of the inner structure is configuredto attach to the headphone; at least a portion of the outer structure isat least one of integral with and coupled to at least a portion of asecond surface of the inner structure; the inner structure is harderthan the outer structure; the outer structure is deformable around theinner structure; and a plane, which is perpendicular to at least one ofthe at least a portion of the first surface and the at least a portionof the second surface, intersects the at least a portion of the firstsurface and the at least a portion of the second surface.
 30. The eartip of claim 29, wherein at least a portion of the inner structurecomprises a greater durometer than at least a portion of the outerstructure.
 31. The ear tip of claim 29, wherein the inner structureextends into an inner cavity of the outer structure.